Warehouse Floor Lifting
THE JOB
25,000 square feet of the industrial floor at a military facility settled up to 4 inches and was affected by sub-slab voids. This warehouse floor lifting project also included 250 track feet of embedded rail, which was set in an independent, thickened slab section. The building had been used for warehousing but was being transitioned to light manufacturing/maintenance.
There were extensive voids below the floor. The voids were located with GPR, and confirmed with cores. Because the floor had cracked extensively as it settled, the designer called for a 4″ un-bonded overlay after stabilization.
THE CHALLENGE
The proposed repair method had to provide adequate bearing capacity for manufacturing and ensure complete void filling and stabilization.
THE SOLUTION
CJGeo provided a value engineering proposal to use geotechnical polyurethane instead of cementitious grout. The VE proposal was based on the following:
- lower unit weight, so less likelihood of causing additional settlement
- adequate strength to ensure uniform load transfer to the underlying soils
- simplified logistics into a secure facility (all material delivered in just two truckloads)
The specified grout had an in-place density exceeding 115 pounds per cubic foot. The proposed polyurethane grout, CJGrout 40NDV, has a constrained density of 5.5PCF, yet a bearing capacity exceeding 12KSF.
CJGeo mobilized three polyurethane grouting crews to the facility, with a combined pumping capacity exceeding 5,000 pounds per hour. CJGeo crews injected the CJGrout 40NDV through nearly 2,000 dime-size holes drilled in the slab to complete this concrete lifting project.
The cutoff criteria for void filling was cross-hole communication or 0.1 inches of lift. The settled areas of floor raised an average of three inches. The embedded track area raised up to four inches.
It took CJGeo fewer than 10 days to complete this warehouse floor lifting job. Because the material cures to 95% within a few minutes, the overlay preparation crew worked a day behind the polyurethane grouting crews.
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Facing a similar challenge to this warehouse floor lifting project? Give us a shout or shoot us a text. Click the state marker for the location of the project for contact info for the appropriate rep.
9″ Floor Lift
THE JOB
9″ floor lift for 6,000 square feet of slab floor in a flex space building in Boston, Massachusetts. The tenant of a warehouse space vacated at renewal due to challenges that the settlement caused for their operations. The tenant of the adjacent office portion threatened to not renew if the warehouse floor wasn’t lifted.
THE CHALLENGE
The building owner wanted to lift the warehouse floor to improve the function of the space. To avoid further upsetting the office tenant, repairs had to be quiet, dust free, not require moving any of their furnishings, and ensure long term stability.
The office space settlement correction repairs could only happen at night, so relying on material deliveries would be difficult.
THE 9″ FLOOR LIFT SOLUTION
CJGeo proposed plural component polyurethane grouting to the owner for this 9″ floor lift. Plural component polyurethane grouting is exceptionally clean, isn’t dependent on third party grout deliveries, and allows immediately return to service.
A five person CJGeo polyurethane grouting crew corrected all of the settlement in a single shift using CJGrout 28FDL. The vacant warehouse portion of the building was lifted during the day. Once the adjacent office closed for the day, the CJGeo crew completed the office space slab foundation repair overnight.
CJGrout 28FDL injection uses 5/8″ holes drilled through the slab. Because the holes are so small, dustless drilling is very easy. During installation, CJGrout 28FDL expands up to 24 times its liquid volume. Therefore, this entire project was done with material delivered to the site in CJGeo’s equipment. Cement grouting would have required multiple material deliveries, which would have made this 9″ floor lift project take much longer.
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Facing a similar challenge to this 9″ floor lift? Give us a shout or shoot us a text. Click the state marker for the location of the project for contact info for the appropriate rep.
